White Paper Effective August 2016

Selecting fluids for hydraulic pumps

Anjeeve George Introduction Fluid Properties to Consider
Lead Engineer
Lubricants Hydraulic fluid is one of the most important Various fluid properties affect the fluids ability
Eaton India components of a hydraulic system. It performs to perform different functions. Viscosity, which
Engineering Center multiple functions, such as power transmission, describes a fluids resistance to flow, is the most
lubrication, heat transfer, and conveyance of important. It accounts for hydrodynamic/boundary
sludge, wear debris, and contamination. lubrication, volumetric efficiency, mechanical
With the important roles played by fluids, proper efficiency, cavitation, quantity of lubricants
fluid selection is critical in maximizing performance reaching lubricated parts, heat generation, and
and life of hydraulic pumps, motors, and other many other properties like air release, heat
components. To make the right choice, a variety dissipation, and filterability.
of fluid properties must be considered, along Low viscosity fluids provide thin film thickness,
with other factors such as operating parameters, leading to boundary lubrication conditions, which
system requirements, environmental conditions, can result in metal-to-metal contact and damage
and regulations. system components. For example, when two
moving metal surfaces contact each other with
How Fluids Affect Pump inadequate lubrication, excessive wear can occur
Performance due to cold welding, as shown in Figure 1, and
damage components. Low viscosity also reduces
Hydraulic components and the hydraulic fluid work volumetric efficiency of pumps and motors
together to run the hydraulic system. Because the through increased internal leakages.
fluid is the medium by which power is transmitted
to perform any usable work, hydraulic systems
simply cannot operate without sufficient fluid.
With the critical role of hydraulic fluid, appropriate
fluid type, viscosity, and quality are essential
requirement for fluid selection. A hydraulic system
with a poorly matched fluid may operate, but
deliver substandard performance, and ultimately
could lead to catastrophic failures. Improper fluid
selection can cause various undesirable results,
such as decreased system efficiency, lack of
lubrication, reduced fluid and component life,
corrosion, erosion, sludge and varnish formation,
and excessive heat generation.
In addition to fluid properties and quality,
contamination also affects system performance
significantly. Contamination can generally originate
from four sources: contaminated oil, built-in
contamination, ingressed contamination, and Figure 1. Low viscosity can allow
internally-generated contamination. It can lead metal-to-metal contact and lead to damaged
to decreased efficiency, component wear, and components.
other adverse impacts. Studies indicate that more
than 70 percent of hydraulic system failures are
due to contamination and can reduce hydraulic
efficiency as much as 20 percent before a system
malfunction is recognized[1].
White Paper
Effective August 2016
On the other hand, high viscosity, or high resistance to flow, can
result in sluggish operation, along with decreased mechanical
efficiency. Energy losses from high viscosity can result in elevated
fluid temperature. High viscosity can cause cavitation and poor air
release properties, resulting in cavitation and aeration erosion, as
shown in Figure 2. In addition, lubricants may not reach areas with
tight clearances, causing failures due to inadequate lubrication.
Figure 2. High viscosity can lead to cavitation and erosion
caused by a collapsing air bubble or vacuum bubble.
The rate of air release varies based on different viscosities and
temperatures. At a given temperature, air is released faster with
lower viscosity fluids, as shown in Figure 3. As the temperature
increases, air is also released faster for each fluid.
20
Air release value (minutes)
10
5 ISO VG 46
2
1
0.5
20 30 40 50 60 70
Temperature(C)
Figure 3. Air release varies based on temperature and viscosity.
Viscosity itself is affected by temperature, with contributing factors
of environment temperature, operating temperature, and system
design. Suitable viscosity grade fluid needs to be selected for each
application based on the operating temperatures. The fluid viscosity
at operating temperature must meet the viscosity recommendations
of the system components, primarily the pump. Minimum, normal,
and maximum operating temperatures need to be considered for
selecting the fluid viscosity grade.
2 EATON www.eaton.com
Selecting fluids for hydraulic pumps
Overall efficiencies of hydraulic components are related to
mechanical efficiency and volumetric efficiency. Mechanical
efficiency is related to frictional losses and drag due to fluid
viscosity, and volumetric efficiency relates to internal leakages.
Both volumetric and mechanical efficiencies depend on the viscosity
of the fluid. As shown in Figure 4, volumetric efficiency increases
with increased viscosity and mechanical efficiency increases with
decreased viscosity. The particular range of viscosity at which
overall efficiency is maximum is typically selected as the optimum
range for the specific components. Viscosity recommendations
should be considered for all system components, but viscosity
recommendations for pumps and motors should be given prime
importance.
Volumetric efficiency
Pump efficiency
Mechanical efficiency
Optimum
operating range Overall efficiency
Viscosity
Figure 4. The optimum operating range of a hydraulic system
depends heavily on fluid viscosity.
Anti-wear (AW) properties of fluids are another crucial parameter
to be considered. Good AW properties are required to maximize
hydraulic system performance and component life. The fluid must
be properly formulated and have adequate AW additives. The AW
ISO VG 32
additives form a thin layer on the mating surfaces and help
prevent metal-to-metal contact at boundary lubrication conditions.
The resulting damages due to lack of AW properties is
depicted in Figure 5.
ISO VG 68
ISO VG 100
80 90
Figure 5. A cam ring of a vane pump was damaged due to lack
of anti-wear properties.
Selecting fluids for hydraulic pumps White Paper
Effective August 2016

Insufficient AW properties can lead to cold welding and scuffing
in the boundary lubrication regime, resulting in removal of surface
material. Anti-wear properties are essential for both rolling and
sliding contact, but the requirement for sliding contacts is more
critical, as stick-and-slip type movement can occur. Even the best
machined surfaces have asperities (hills and valleys). When the
asperities come in contact at heavy load, they can become joined
by cold welding. If the applied force is large enough to break the
welding, the object suddenly moves. This causes material removal
from surfaces. High additive reserve is recommended for severe
applications, to allow the surfaces to slide or roll over each other
without any surface damage, as shown in Figure 6.
The Eaton-Vickers 35VQ25 pump test was developed to
demonstrate a fluids ability to protect components from wear,
thereby confirming long-term use in various operating conditions, as
shown in Figure 7. The test was adopted by the American Society
for Testing and Materials (ASTM) with the designation of ASTM
D6973 (Standard Test Method for Indicating Wear Characteristics of
Petroleum Hydraulic Fluids in a High Pressure Constant Volume
Vane Pump).

High speed/high load

Surface slide over other
Lubricant
film

Adhesion (cold welding)

Figure 7. Eaton-Vickers 35VQ25 pump test stand made at Eaton
India facility.

The 35VQ pump test can be used to evaluate anti-wear properties of

hydraulic fluids. Higher performance fluids can dramatically reduce
wear and extend the life of components, as represented in Figure 8.
AW/EP High speed/high load
Additive Surfaceslide over other
Extended 35VQ25 pump test
ISO 32, 220F
6000

5000
Total wear(mg)

4000

3000

2000

1000

0
Figure 6. Anti-wear additives can help surfaces slide over each 0 200 400 600 800 1000 1200 1400 1600
other and avoid stick-and-slip movement. Time on oil (hours)

High performance Normal performance Extrahigh performance

Figure 8. Results of the 35VQ25 pump test various fluids.

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Other properties to consider include:
Viscosity Index (VI) - Empirical, unit-less number indicating
the effect of temperature change on the kinematic viscosity
of an oil. Liquids become less viscous when heated. A high VI
indicates a relatively small change of viscosity with temperature.
High VI (multi-grade) fluids are recommended for applications
at wide operating temperatures or at extreme environmental
conditions. In general, high VI fluids are recommended for mobile
applications, as they are exposed to environmental changes and
high operating temperatures.
Shear stability - This is the measure of a fluids resistance to
shearing. Polymers known as VI improvers are used to make high
VI fluids. The molecules of VI improvers break down to smaller
molecules, causing thinning of viscosity, also known as shearing.
Shear stability is the most important property of a VI improver.
VI improvers with low shear stability will quickly break down,
resulting in thinning of oil. Viscosity after shear also needs to be
considered for applications with VI improved fluids.
Thermal and oxidative stability - Oxidation is chemical reaction
of oxygen with oil, generating acidic byproducts. The rate of
oxidation is accelerated by high temperatures, water, acids
generated due to oxidation, and presence of metal catalysts
such as copper. The rule of thumb is: oxidation doubles with
increase of temperature by every 10oC. Oxidation will lead to
increased viscosity, total acid number (TAN), generation of varnish
and sludge, and darkening of fluid. The rate of oxidation can be
reduced by reducing fluid temperature and using fluids formulated
with quality base stocks, anti-oxidant additives, and thermally
stable AW additives.
Hydrolytic stability - Hydrolysis is chemical degradation of
lubricants by reaction with water. Lubricant additives, especially
zinc-based additives, will react with water, forming acidic
by-products. The presence of metals such as copper can act as
a catalyst. Ester-type base stocks also hydrolyze in presence
of water. Lubricants with good hydrolytic stability will resist
hydrolysis.
Filterability - Fine filters used in hydraulic systems may exhibit
premature filter plugging due to inappropriate formulations, water
contamination, and fluid degradation. Measurement of filterability
helps predict fluid behavior in filtration applications, before use in
a system.
Demulsibility - The ability to release water from a water-oil
mixture. This characteristic is important for the equipment
operating in humid climates, where the possibility of water
contamination is high.
Rust and corrosion inhibition - Hydraulic fluids are generally
formulated with rust and corrosion inhibitors. The rust inhibitors
get deposited as thin film on the metal surfaces and enable
protection from rust. The corrosion additives hinder hydrolysis
and prevent formation of acidic materials which causes corrosion.
The ability of a fluid to prevent rust and corrosion can be
measured by a rusting test using distilled water, salt water,
and a steel specimen.
Material compatibility - Different rubber and elastomer
components, including hoses, accumulator bladders, seals,
and gaskets, are used in hydraulic systems and have different
compositions, or recipes. Because of these varying compositions,
fluids are tested for their compatibility with most commonly
used elastomers to predict the life and performance with that
particular fluid.
Air release - Suspended entrained air can cause many
abnormalities such as poor system efficiency, system failure
through erosion (similar to cavitation), and fluid degradation
through micro-dieseling. Micro-dieseling occurs when air bubbles
move from a low- or negative-pressure area to a high-pressure
4 EATON www.eaton.com
Selecting fluids for hydraulic pumps
area, get heated up due to compression, and carbonize oil at the
bubble interface, resulting in carbon byproducts and oxidation. Air
release characteristics have more significance in systems with
relatively short residue time. An air-release test can identify the
ability of a lubricant to separate entrained air.
Foaming tendency - Foaming is a common problem for
hydraulic systems. Large volumes of foam can cause overflow
of reservoirs. Factors that lead to foaming are contamination,
degraded fluid, air entrainment, and poor system design. Hydraulic
fluid formulations contain foam inhibitors, but very higher dosages
can give adverse effect. Foaming tendency test describes the
volume of foam generated immediately after the fluid is agitated
and aerated. Foam stability measures the volume of foam
remaining after a specific time from the stoppage of aeration.
Volatility - Volatility is the tendency of a fluid to vaporize rapidly.
While generally not as critical for hydraulic fluids as for motor
oils due to limited or no exposure to high temperatures and
lower operating temperatures of hydraulic fluids, volatility is
still a parameter to consider. Mineral base oils are mixtures of
hydrocarbons of different size. At high operating temperatures,
smaller molecules may escape from the oil, decreasing oil volume
and increasing fluid viscosity. Improper base oil selection and
blending can lead to higher volatility.
How to Select the Right Fluid
A properly selected fluid meets the requirements of the various
properties mentioned above in a balanced manner. Because
identifying and interpreting all fluid requirements for a common
user is difficult, Eaton has developed a full-fledged specification
that cover requirements of hydraulic fluids and stipulate base stock
requirements, physical properties, and performance requirements for
both conventional and zinc-free hydraulic fluids, along with material
compatibility with rubber materials. Fluids meeting this specification
have been considered good quality hydraulic fluids[2]. Most oil/
additive manufacturers follow Eatons specification and print the
same on their catalogs and on oil containers, so that the common
users can identify quality lubricants easily.
Eaton has developed fluid recommendations with for Eaton hydraulic
products, such as Hydraulic Fluid Recommendations, which
provides basic guidelines for selecting hydraulic fluid. The document
provides viscosity recommendations and cleanliness requirements
for Eaton hydraulic products[3].
Numerous lubricants other than conventional hydraulic fluids are
used in hydraulic systems, such as motor oil, automatic transmission
fluids, universal tractor transmission oil (UTTO), and super tractor
oil universal (STOU). Some of these are formulated with mineral/
petroleum-base oils, while others are synthetic-base such as those
using a polyalphaolefin (PAO) base. Most Eaton components are
rated with these fluids
While hydraulic pumps are generally designed to operate with
mineral-base fluids, alternative fluids are sometimes used for
applications where certain special properties are essential, perhaps
even more important than hydraulic system performance.
For specific applications such as environmentally friendly and fire-
resistant applications, certain alternate fluids such as phosphate
esters, polyol esters, polyether polyols, polyalkylene glycols,
vegetable oil base fluids, water glycol, and invert emulsions, are
sometimes used. For example, if fire resistance is critical, fire-
resistant properties may be the most important factor. Similarly,
in environmentally sensitive applications, the focus may be on
biodegradability and toxicity. Other fluid types, such as food-grade
fluids and military specification fluids, are sometimes used in
hydraulic applications.
Selecting fluids for hydraulic pumps
Each alternative fluid may have certain advantages for the specified
application, but their fundamental properties, such as lubrication,
coefficient of friction, pressure viscosity coefficient, vapor pressure,
specific gravity, and low temperature properties, may not be
equivalent to those of mineral-base lubricants. Therefore, hydraulic
components, especially pumps and motors may need to be de-rated
to account for these adverse factors.
To determine whether a special or alternative fluid is warranted,
ask some key questions, such as:
Is the hydraulic application near an ignition source or high
temperature surfaces, where fluid leakage could cause a fire?
Are fire suppression measures potentially ineffective or
impractical?
Would a fire result in unacceptable impacts or costs?
Are there any insurance benefits to using a fire-resistant fluid?
Does the system work in an environmentally sensitive area, such
as agriculture areas or forests, or where environmental regulations
are applicable?
Does the system need to be operated near or within waterways
such as rivers, canals, or oceans or water sources, such as dams
and reservoirs?
Could leakage of oil cause damage to the environment, which
could be a punishable offense?
Does the application have any non-standard requirements such as
military or aerospace?
If the answer is yes to any of these questions, the system may
require a special fluid.
Impacts of Using the Wrong Fluid
What happens if an improperly matched fluid is used in a pump?
The answer can vary, depending on the degree of mismatch.
As noted earlier, fully formulated fluids should have balanced
properties. Excessive variation in any given parameter can cause
direct or indirect impacts. For example, a fluid incompatible with
certain rubber materials may cause failure of gaskets and other
components, as shown in Figure 9.
Figure 9. Rubber gasket extruded due to excess elongation
caused by incompatible fluid.
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Effective August 2016
A single issue can cause catastrophic failure. For example, poorly
maintained systems may fail catastrophically due to one or more
reasons. Contamination, along with incompatible fluids, can lead
to component failures, as shown in Figure 10. Any undesirable
matter in the fluid is a contaminant and could be particulate matter,
water, air, or other lubricants. The Eaton document The Systemic
Approach to Contamination Control provides more information on
contamination and its control[1].
Figure 10. Contamination, lack of lubrication, and material
incompatibility contributed to the failure of this piston shoe.
Summary
Key points to consider when selecting fluids include the
following:
Select an appropriate viscosity grade to ensure that the
fluid viscosity at operating temperatures meets viscosity
recommendations of the components, particularly for pumps.
Fluids must pass Eaton 35VQ25 pump test and satisfy Eaton
E-FDGN-TB002-E fluid specification requirements.
Follow Eatons established pump ratings for applications with
alternate fluids.
With the proper fluid selection and adequate contamination
control practices, end users can achieve reliable operation of
pumps for many years.
Do not assume that a new hydraulic oil is clean; it could be
contaminated.
Transfer oil to hydraulic system reservoir only through filter carts.
Do not mix the fluid with any other type/brand/viscosity grade
fluid, as it may cause gelation, additive precipitation, miscibility,
filter blockage, and viscosity change.
Clean and flush hydraulic system including reservoir if any
component fail catastrophically. The particles generated may
damage other components.
Isolate contamination-sensitive components before flushing the
hydraulic system.
Contamination limit should be maintained throughout the fluid life.
Select filter ratings based on the system cleanliness
requirements.
Flush the system with the fresh fluid, even after cleaning the
system manually.
For changing to a different type fluid, clean the system thoroughly,
and flush with the fresh fluid to avoid any contamination with the
previous fluid used.
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White Paper Selecting Fluids for Hydraulic Pumps
Effective August 2016

Entrained air can cause micro-dieseling resulting high fluid References

temperature and rapid fluid degradation. Bleed the system
properly after refilling and arrest air entrainment.
Excessive foaming in the reservoir is a sign of aeration.
Use desiccant breather in high humidity or marine environments
to avoid water contamination
Water absorbent filters can be used for removing small quantities
of water contamination. Other water removal techniques may use,
if the water contamination is substantially high.
Resources for Assistance
1. The Systemic Approach to Contamination Control:
A Complete Guide for Maximum System Performance,
Eaton Vickers, 2002 (http://www.eaton.in/ecm/groups/public/
@pub/@eaton/@hyd/documents/content/ct_233707.pdf).
2. Eaton hydraulic fluid specification E-FDGN-TB002-E
3. Hydraulic Fluid Recommendations, (Eaton Document
03-401-2010), Eaton, 2013
(http://www.eaton.com/ecm/groups/public/@pub/@eaton/
@hyd/documents/content/pct_500331.pdf).

With all the properties to consider, fluid selection may seem like a
daunting process. For assistance, contact your Eaton representative
or Eatons lubricant specialist for pump/motor ratings with different
alternate fluids. As an additional resource, the Eaton Lubricant Help
Desk can offer assistance in defining fluid requirements, identifying
available documentation, and other technical support.
About Eaton
Eaton is a power management company with 2015 sales of
$20.9 billion. Eaton provides energy-efficient solutions that
help our customers effectively manage electrical, hydraulic and
mechanical power more efficiently, safely and sustainably. Eaton has
approximately 97,000 employees and sells products to customers
in more than 175 countries.
For more information, visit www.eaton.com.

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